Abstract: A laser power control method for additive manufacturing includes a pre-processing component and an intra-processing component. The pre-processing component creates in the system controller a machine code expressed additive-path-with-geometry-metadata that includes a path description. The path description represents the path of the beam source on the build and includes a geometry index for the build. The intra-processing component calculates required power for the beam at intervals and events on the beam path based upon the additive-path-with-geometry-metadata and calculations of the energy balance at the melt pool and the total energy for each point P(s) on the path.

Abstract: A method for controlling, during metal processing, the input energy from an energy point source that directs focused emitted energy onto a metal workpiece having a geometry, wherein the directed focused emitted energy creates a melt pool and hot zone on the workpiece that emit radiation during the process. The method comprises determining a wavelength range for the emitted radiation that is within a spectral range of radiation emitted by the hot zone during processing that is comparatively high in amount in relation to the amount of radiation emitted by the melt pool in that spectral range during processing; directing the beam onto the workpiece to generate a melt pool and hot zone on the structure; measuring the intensity of radiation within the determined wavelength range; and adjusting the input energy from the energy point source based upon the measured intensity of radiation within the determined wavelength range.

Abstract: An apparatus for feeding powder particles includes a hopper holding a supply of powder. A voltage supply is in electrical communication with a first electrode and a second electrode. The hopper is configured to drop powder onto the first electrode. The voltage supply is capable of producing an electric potential between the first electrode and second electrode and causing the powder particles landing on the first electrode to develop a surface charge. The second electrode is positioned remotely from the first electrode such that the electric field between the first electrode and the second electrode causes the powder particles that fall onto the first electrode to move off the first electrode and move toward the second electrode. The powder particles moving toward the second electrode may or may not reach the electrode, but in either case drop away from the second electrode due to the force of gravity.

Abstract: A build description is created for a part intended to be built by additive layering. The build description includes a description of the part broken down into constituent substructures and a build sequence for the substructures. A power schedule calculation method utilizes the build description and an idealized geometry to predict laser power levels on an additive path during laser deposition. The method calculates beam power for any point along the path traveled to form the build. Each point along the path has associated with it an idealized geometry comprising a melt pool, hot zone and bulk portion.

Abstract: An apparatus for feeding powder particles includes a hopper holding a supply of powder. A voltage supply is in electrical communication with a first electrode and a second electrode. The hopper is configured to drop powder onto the first electrode. The voltage supply is capable of producing an electric potential between the first electrode and second electrode and causing the powder particles landing on the first electrode to develop a surface charge. The second electrode is positioned remotely from the first electrode such that the electric field between the first electrode and the second electrode causes the powder particles that fall onto the first electrode to move off the first electrode and move toward the second electrode. The powder particles moving toward the second electrode may or may not reach the electrode, but in either case drop away from the second electrode due to the force of gravity.

Abstract: A method for controlling, during metal processing, the input energy from an energy point source that directs focused emitted energy onto a metal workpiece having a geometry, wherein the directed focused emitted energy creates a melt pool and hot zone on the workpiece that emit radiation during the process. The method comprises determining a wavelength range for the emitted radiation that is within a spectral range of radiation emitted by the hot zone during processing that is comparatively high in amount in relation to the amount of radiation emitted by the melt pool in that spectral range during processing; directing the beam onto the workpiece to generate a melt pool and hot zone on the structure; measuring the intensity of radiation within the determined wavelength range; and adjusting the input energy from the energy point source based upon the measured intensity of radiation within the determined wavelength range.

Abstract: A build description is created for a part intended to be built by additive layering. The build description includes a description of the part broken down into constituent substructures and a build sequence for the substructures. A power schedule calculation method utilizes the build description and an idealized geometry to predict laser power levels on an additive path during laser deposition. The method calculates beam power for any point along the path traveled to form the build. Each point along the path has associated with it an idealized geometry comprising a melt pool, hot zone and bulk portion.